Apparatus for inhibiting corrosion of articles with metal surfaces

ABSTRACT

A molded VCI lid inhibits corrosion of metal surfaces on articles in a recloseable container. A method includes providing a molded VCI lid for inhibiting corrosion of metal surfaces on articles in a recloseable container.

This application is based upon and claims priority from U.S. Provisional application Ser. No. 62/915,961, which is incorporated herein by reference.

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates to corrosion inhibitors, and methods for inhibiting corrosion of articles with metal surfaces.

The invention is particularly applicable to method and apparatus for inhibiting corrosion of metal surfaces on consumable articles that are delivered to the user in a container with VCI product, are of a type or supplied in a quantity wherein the articles are consumed over a period of time, and that may be stored in the original container after its initial opening until all articles are consumed.

Background Information

Volatile Corrosion Inhibitors (VCI) are well known in the industry. They emit a vapor intended to fill a space and coat the metal surfaces of articles in the space to inhibit corrosion of the surfaces, and/or blend with moisture and oxygen in the space to neutralize the primary components (i.e., moisture and oxygen) that cause corrosion.

VCI compounds are provided in a variety of commercial products. Some of the more common commercial products are fibrous products such as VCI impregnated paper, cloth sheets, and small wood pulp, fiberboard or paperboard chips. VCI compounds are sometimes mixed with other chemicals, oils and other carriers for physically coating the surfaces of articles that may be susceptible to corrosion. VCI compounds are also mixed with plastic and other polymer resins for producing corrosion inhibiting products such as polyolefin film and bags, foam sheets and foam tape, and molding into plastic, rubber or other elastomer parts. Some other common polymers that VCI compounds are used with include, but are not limited to, polypropylene, polyethylene, polystyrene and a 4 methyl 1 pentane compound.

The various VCI products have well known advantages and disadvantages. Impregnated paper is generally the least expensive and most readily available VCI product. The expulsion of corrosion inhibiting vapor from paper and other fibrous VCI products is typically much faster than from the molded VCI products. Consequently, the vapor from a VCI impregnated fibrous product will fill a space at a faster rate than vapor from a molded product. Relatively fast saturation of a space by fibrous VCI products also makes them suitable for use in semi-closed and semi-controlled environments.

Molded VCI products are most suitable for closed and controlled environments, and generally offer a longer life and greater resilience from the elements in such environments. On the other hand, molded VCI products are also typically more expensive than the fibrous VCI products.

A manufacturing environment with temperature and element control, reducing the exposure to corrosion causing elements prior to packaging of articles, would be a controlled environment. A closed container in which articles are packaged would a closed environment. Semi-controlled and un-controlled environments are typically found in the retail or consumer after markets, or at the location of the product end user. An un-controlled environment would include a tool box that is not sealed and may be exposed to corrosion causing elements, such as boxes being left open in the rain or stored in the open bed of trucks, boats or in the trunk of a car.

VCI products are included with articles in sealed containers to inhibit corrosion of OEM packaged articles while in shipping and storage. When a container is thereafter opened and its contents removed, the VCI product is thrown away with the packaging; the purpose of the VCI product has been fulfilled when the article is removed from the package.

In certain instances, not all articles are removed when a package is initially opened. For example, welding electrodes are typically packed with multiple electrodes in a container, whereas the electrodes may only be removed one or two at a time, over a period of several months. Many other articles, particularly those used in industry, are packaged in quantities greater than what may be used at one time by the typical user. In such instances, the articles are typically packaged in a recloseable container such that the user can remove a desired quantity from the container, and re-close the container for storage of the remaining articles until they are needed.

In this scenario, articles remaining in the container after it is initially opened will be protected from corrosion if sufficient corrosion inhibiting vapor develops in the container after it is closed. However, this if often not the case. The OEM is primarily concerned with inhibiting corrosion until the articles reach the user. The VCI product initially packed with the articles will presumably be sufficient to achieve this purpose in the closed environment of the sealed OEM container. However, once the container is opened, the corrosion inhibiting vapor that was initially in the container is quickly dispersed into the atmosphere. If the initially packaged VCI product does not have sufficient vapor emitting capability to re-saturate the (now increased) space inside the container after articles are removed and the container closed, then the articles remaining in the container will not be sufficiently protected against corrosion during subsequent storage. This is often the case, particularly where articles are packaged with the less expensive fibrous VCI products. In such instance, the lack of sufficient corrosion inhibiting vapor will only increase each time the container is opened and then closed again. Thus, each time an article is removed from the container, the remaining articles are more susceptible to corrosion.

The present invention addresses the above-described drawbacks in relation to inhibiting corrosion of consumable articles packaged in quantities greater than what may be entirely used upon initial opening of the OEM packaging. The present invention addresses certain other drawbacks and disadvantages of prior VCI products.

SUMMARY OF THE INVENTION

The principle objective of the invention is to provide new and unique corrosion inhibitors, and methods for inhibiting corrosion of articles with metal surfaces.

A more detailed objective of the invention is to achieve the foregoing in method and apparatus for inhibiting corrosion of metal surfaces on consumable articles that are delivered to the user in a container with VCI product, are of a type or supplied in a quantity wherein the articles are consumed over a period of time, and that may be stored in the original container after its initial opening until all articles are consumed.

This and other objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

Briefly, one aspect of the invention involves provision of molded VCI lid for a container filled with articles to be protected from corrosion.

Another aspect of the invention involves replacing an OEM lid on a container filled with articles and other VCI product with a molded VCI lid for protection of the articles from corrosion after the container has been initially opened.

Another aspect of the invention involves providing a molded VCI lid, together with, but not installed on the OEM container.

Another aspect of the invention involves providing a molded VCI lid pre-installed on the OEM container.

Another aspect of the invention involves providing a molded VCI lid with increased volume of corrosion inhibiting chemicals and enhanced internal vapor emitting surface area to enhance the speed at which the articles in the re-closed container are surrounded by corrosion inhibiting vapors.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of a recloseable container with a container body and a lid, the container being suitable for holding various articles and VCI product in a closed environment to inhibit corrosion of metal surfaces on the article during transport and storage.

FIG. 2 is a perspective of the container shown in FIG. 1, but with the lid removed from the container body for viewing an access opening, and articles and VCI product in the container.

FIG. 3 is a perspective view similar to FIG. 2 of the container, but with a couple of articles removed from the container, and with a VCI lid in accordance with one aspect of the invention.

FIG. 4 is a cross-sectional view of the VCI lid shown in FIG. 3.

FIG. 5 is a perspective view similar to FIG. 1 of an alternate recloseable container with a container body and a lid, the container being suitable for holding various articles and VCI product in a closed environment to inhibit corrosion of metal surfaces on the article during transport and storage.

FIG. 6 is a perspective of the container shown in FIG. 4, but with the lid removed from the container body for viewing an access opening, and articles and VCI product in the container.

FIG. 7 is a perspective view similar to FIG. 4 of the container, but with a couple of the articles removed from the container, and with a VCI lid in accordance with one aspect of the invention.

FIG. 8 is a cross-sectional view of the VCI lid shown in FIG. 7.

FIG. 9 is a perspective view of an alternate VCI lid in accordance with the invention and suitable for use with the container shown in FIGS. 5-7, and suitable for replacing the OEM lid on the container.

FIG. 10 is a cross-sectional view of the VCI lid shown in FIG. 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the figures, FIG. 1 is a perspective of a recloseable container 10 with a container body 12 and a lid 14. The container is suitable for holding various articles and VCI product in a closed environment to inhibit corrosion of metal surfaces on the articles during transport and storage. The lid is shown in position on the top of the container body, closing an access opening through which the articles in the container can be removed.

The container, sealed with the lid and with a VCI inside, may be filled with articles to be protected from corrosion, such as one or more of: welding consumables, welding rods, wire, brazing, tool and die repair, consumables for shielded metal arc welding, consumables for gas metal arc welding, consumables for gas tungsten arc welding, or consumables for oxyacetylene welding. The container, sealed with the lid and with a VCI inside, keeps the stored articles safe from air and moisture contamination that causes corrosion.

FIG. 2 is a perspective of the container 10 with the lid 14 removed from the top of the container body, as for removing articles 2, which are surrounded by VCI product 4, through the access opening 16. On this particular container, the lid includes a closed top and a cylindrical skirt 14 a depending therefrom that snugly slips over and around a lip 12 a surrounding the access opening at the top of the container body.

The invention may be practiced with many types and configurations of containers, including containers made from, for example, metal or plastic, and, for example, with lids threaded onto the container body. The articles 2 shown are metal rods, such as welding electrodes, standing on end in the container. The VCI product 4 shown is paper impregnated with corrosion inhibiting compounds, wrapping the electrodes in the container.

During OEM packaging, the electrodes and VCI paper are sealed in the container body by the lid 14. The VCI paper emits a vapor that fills the space in the closed container to inhibit corrosion of the electrodes during transport and storage.

When the user wants an electrode, the user removes the lid from the container body, removes an electrode from the container, and then replaces the lid to close the container for storage of the unused electrodes. Thereafter, each time another electrode is needed, the lid is removed from the top of the container, an electrode removed from the container body, and the lid replaced on the container for further storage of the unused electrodes, until all of the electrodes have been used.

When the container is initially opened by the user, the corrosion inhibiting vapor inside the container dissipate into the atmosphere. If the VCI paper contains sufficient additional vapor emitting capability, closing the container after removal of an electrode will enable the paper to fill the space in the container with corrosion inhibiting vapor, to inhibit corrosion of the electrodes remaining in the container.

FIG. 3 is a perspective view of the container 10 with the lid 14 removed, and a couple of electrodes removed from the container. As will be noted, if the container is initially fully packed with the rods and paper (as represented in FIG. 2), removal of only a couple of electrodes can result in a significant increase in space inside the container.

As a result, in order for the VCI paper to emit sufficient corrosion inhibiting vapor to protect electrodes remaining in the container after initial removal of one or two electrodes, the paper must emit significantly more vapor than what was required at the time of initial packaging. And each time the container is opened and an electrode removed, the vapor previously in the container is dissipated into the atmosphere, and the space in the container is similarly increased. As a result, the paper must emit an increasingly significant amount of corrosion inhibiting vapor to protect the remaining electrodes in the container.

However, as discussed above, often times the VCI paper packed with the articles will not have sufficient corrosion inhibiting, vapor emitting capability to re-saturate the increasing space inside the container after articles are removed to protected against corrosion during subsequent storage.

In accordance with the invention, a molded VCI lid 18 is provided in a configuration to replace the OEM lid 14, and close the top of the container body, after the container is opened. The VCI lid 18 is molded from plastic, rubber, polymer or other elastomer, with sufficient corrosion inhibiting compound to re-saturate the increasing space inside the container after articles are removed, and thereby protect the articles against corrosion during subsequent storage in the container.

As shown in FIG. 4, the preferred VCI lid 18 is a solid VCI lid; molded with the corrosion inhibiting compound throughout the thickness of the lid. In other words, the lid is not laminated or layered with, for example, an inside VCI layer and an outside non-VCI layer. This preferred arrangement of a solid VCI lid enables a less costly production, including a single step molding process, as compared with a laminated or layered lid that will typically require a twostep production, such as two-step molding or placement of an insert into the mold prior to injection or placement of the VCI resin into the mold.

In carrying out one aspect of the invention, the OEM lid 14 is disposed of, as indicated by arrow A, after the container is initially opened (or after subsequently opened when the vapor emitting capability of the paper is insufficient to thereafter protect the articles from corrosion), and is replaced by the VCI lid 18 to re-close the container as indicated by arrow B. The VCI lid 18 need not be an exact replica of lid 14, but it is molded with sufficiently matching interface structure in relation to the top of the container body to fit onto and close the container as did the lid 14. In the embodiment shown, the lid 18 includes a closed top and a cylindrical skirt 18 a depending therefrom to snugly slip over and around the lip 12 a surrounding the access opening at the top of the container body.

In carrying out another aspect of the invention, the container 10 is supplied with the lid 14 installed onto the container body, and with the VCI lid 18 not installed, such as in a separate plastic bag taped to or otherwise associated with the container such that the VCI lid is delivered to the user with the container. This enables OEM packaging with the less expensive but quick-acting VCI paper, and inhibits loss of vapor from the VCI lid 18 until such time as the end user opens the container and replaces the lid 14 with the VCI lid 18. As a result, this achieves the longest lasting corrosion inhibiting characteristics, taking advantage of the paper prior to the container being opened, and essentially saving the corrosion inhibiting life of the VCI lid until the container is opened by the user.

In carrying out another aspect of the invention, the VCI lid 18 is pre-installed onto the container body. This eliminates the need for the non-VCI lid 14, and would be particularly applicable when the welding rod containers, which are initially filled with a noble gas are opened and the noble gas is lost. When reclosed, the pre-installed VCI foam in the container body would eliminate the need to add a VCI lid and a standard lid could be used, or having to place the welding rod container in a heated, humidity controlled container or environment.

FIG. 5 is a perspective of an alternate recloseable container 30 with a container body 32 and a lid 34. The container is suitable for holding various articles and VCI product in a closed environment to inhibit corrosion of metal surfaces on the articles during transport and storage. The lid is shown in position on the top of the container body, closing an access opening through which the articles in the container can be removed.

FIG. 6 is a perspective of the container 30 with the lid 34 removed from the top of the container body, as for removing articles 2, which are surrounded by VCI product 4, through the access opening 36. On this particular container, the lid includes a center plug 34 a that slips snugly into the access opening in the container, and a surrounding shoulder 34 b to engage the top of the container body when the plug is positioned in and closing the access opening in the container body. The articles 2 and VCI product 4 are as previously described in connection with container 20.

During OEM packaging, the electrodes and VCI paper are sealed in the container body by the lid 34. The VCI paper emits a vapor that fills the space in the closed container to inhibit corrosion of the electrodes during transport and storage.

When the user wants an electrode, the user removes the lid from the container body, removes an electrode from the container, and then replaces the lid to close the container for storage of the unused electrodes. Thereafter, each time another electrode is needed, the lid is removed from the top of the container, an electrode removed from the container body, and the lid replaced on the container for further storage of the unused electrodes, until all of the electrodes have been used.

When the container is initially opened by the user, the corrosion inhibiting vapor inside the container dissipate into the atmosphere. If the VCI paper contains sufficient additional vapor emitting capability, closing the container after removal of an electrode will enable the paper to fill the space in the container with corrosion inhibiting vapor, to inhibit corrosion of the electrodes remaining in the container.

FIG. 7 is a perspective view of the container 30 with the lid 34 removed, and a couple of electrodes removed from the container. As will be noted, if the container is initially fully packed with the rods and paper (as represented in FIG. 6), removal of only a couple of electrodes can result in a significant increase in space inside the container.

As a result, in order for the VCI paper to emit sufficient corrosion inhibiting vapor to protect electrodes remaining in the container after initial removal of one or two electrodes, the paper must emit significantly more vapor than what was required at the time of initial packaging. And each time the container is opened and an electrode removed, the vapor previously in the container is dissipated into the atmosphere, and the space in the container is similarly increased. As a result, the paper must emit an increasingly significant amount of corrosion inhibiting vapor to protect the remaining electrodes in the container.

However, as discussed above, often times the VCI paper packed with the articles will not have sufficient corrosion inhibiting, vapor emitting capability to re-saturate the increasing space inside the container after articles are removed to protected against corrosion during subsequent storage.

In accordance with the invention, a molded VCI lid 38 is provided in a configuration to replace the OEM lid 34, and close the top of the container body, after the container is opened. The VCI lid 38 is molded from plastic, rubber, polymer or other elastomer, with sufficient corrosion inhibiting compound to re-saturate the increasing space inside the container after articles are removed, and thereby protect the articles against corrosion during subsequent storage in the container.

As shown in FIG. 8, the preferred VCI lid 38 is a solid VCI lid; molded with the corrosion inhibiting compound throughout the thickness of the lid. In other words, the lid is not laminated or layered with, for example, an inside VCI layer and an outside non-VCI layer. This preferred arrangement of a solid VCI lid enables a less costly production, including a single step molding process, as compared with a laminated or layered lid that will typically require a twostep production, such as two-step molding or placement of an insert into the mold prior to injection or placement of the VCI resin into the mold.

In carrying out one aspect of the invention, the OEM lid 34 is disposed of, as indicated by arrow A, after the container is initially opened (or after subsequently opened when the vapor emitting capability of the paper is insufficient to thereafter protect the articles from corrosion), and is replaced by the VCI lid 38 to re-close the container as indicated by arrow B. The VCI lid 38 need not be an exact replica of lid 34, but it is molded with sufficiently matching interface structure in relation to the top of the container body to fit onto and close the container as did the lid 34. In the embodiment shown, the lid 38 includes a center plug 38 a that slips snugly into the access opening in the container, and a surrounding shoulder 38 b to engage the top of the container body when the plug is positioned in and closing the access opening in the container body.

In carrying out another aspect of the invention, the container 30 is supplied with the lid 34 installed onto the container body, and with the VCI lid 38 not installed, such as in a separate plastic bag taped to or otherwise associated with the container such that the VCI lid is delivered to the user with the container. This enables OEM packaging with the less expensive but quick-acting VCI paper, and inhibits loss of vapor from the VCI lid 38 until such time as the end user opens the container and replaces the lid 34 with the VCI lid 38. As a result, this achieves the longest lasting corrosion inhibiting characteristics, taking advantage of the paper prior to the container being opened, and essentially saving the corrosion inhibiting life of the VCI lid until the container is opened by the user.

In carrying out another aspect of the invention, the VCI lid 38 is pre-installed onto the container body. This eliminates the need for the non-VCI lid 34, and would be particularly applicable when the non-VCI lid (which is originally sealed to the container), which can eliminate the need for the manufacturer to add noble gas to the container.

FIG. 9 is a perspective view of an alternate VCI lid 58 suitable for use with container 30, provided in a configuration to replace the OEM lid 34, and close the top of the container body, after the container is opened. The VCI lid 58 is molded from plastic, rubber, polymer or other elastomer, with sufficient corrosion inhibiting compound to re-saturate the increasing space inside the container after articles are removed, and thereby protect the articles against corrosion during subsequent storage in the container.

As shown in FIG. 10, and for the reasons stated above in relation to the VCI lid 38, the preferred VCI lid 58 is a solid VCI lid; molded with the corrosion inhibiting compound throughout the thickness of the lid.

In carrying out one aspect of the invention, the OEM lid 34 is disposed of after the container is initially opened (or after subsequently opened when the vapor emitting capability of the paper is insufficient to thereafter protect the articles from corrosion), and is replaced by the VCI lid 58 to re-close the container. The VCI lid 58 need not be an exact replica of lid 34, but it is molded with sufficiently matching interface structure in relation to the top of the container body to fit onto and close the container as did the lid 34. In the embodiment shown, the lid 58 includes a center cover 58 a that extends over the access opening in the container, and a surrounding, downwardly depending shoulder 58 b to slip snugly into the outer lip 32 a at the top of the container body and thereby close the access opening in the container body.

In carrying out another aspect of the invention, the container 30 is supplied with the lid 34 installed onto the container body, and with the VCI lid 58 not installed, such as in a separate plastic bag taped to or otherwise associated with the container such that the VCI lid is delivered to the user with the container. This enables OEM packaging with the less expensive but quick-acting VCI paper, and inhibits loss of vapor from the VCI lid 58 until such time as the end user opens the container and replaces the lid 34 with the VCI lid 58. As a result, this achieves the longest lasting corrosion inhibiting characteristics, taking advantage of the paper prior to the container being opened, and essentially saving the corrosion inhibiting life of the VCI lid until the container is opened by the user.

In carrying out another aspect of the invention, the VCI lid 58 is pre-installed onto the container body. This eliminates the need for the non-VCI lid 34.

In carrying out yet another aspect of the invention, the center cover 58 a of VCI lid 58 is a domed cover to provide increased volume of molded material to carry an increased volume of corrosion inhibiting compounds, and enhanced internal (i.e., facing the opening in the container body) vapor emitting surface area to enhance the speed at which the lid 58 will re-fill the space in the container body with corrosion inhibiting vapors.

In view of the foregoing and the accompanying drawings, those skilled in the art will recognize that the other methods and apparatus, in accordance with the invention, including provision of a VCI lid, may be provided in alternate embodiments, not specifically shown or described, in order to enhance protection of articles in a container when the entire contents of the container is not used or consumed at the time the container is initially opened.

From the foregoing, it will be apparent that the present invention brings to the art new and unique method and apparatus for inhibiting corrosion of articles with metal surfaces, and is particularly applicable in connection with consumable articles in a recloseable container.

Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention. 

I claim:
 1. A container for carrying articles to be protected from corrosion, comprising: a body having an interior space and an access opening; at least one of said articles inside said space; a lid; wherein said lid is sized to seal said access opening; wherein said lid can removably attach to said container access opening; wherein said lid can be removed from said container and is recloseable; and a VCI product inside said space.
 2. The container of claim 1: wherein said body is sealed with said lid and with a VCI inside; and wherein stored articles are kept safe from air and moisture contamination that causes corrosion.
 3. The container of claim 1, wherein said lid is molded.
 4. The container of claim 3, wherein a VCI is present throughout said lid.
 5. The container of claim 1, wherein said VCI product is paper impregnated with VCI.
 6. The container of claim 1, wherein said VCI product is attached to said lid.
 7. The container of claim 1, further comprising: a multiplicity of said articles; wherein said lid has an increased volume of VCI and enhanced internal vapor emitting surface area; and wherein there is a sufficient amount of said VCI to re-saturate said space inside said container after some of said articles are removed, and thereby protect said articles that remain in said container against corrosion during subsequent storage.
 8. The container of claim 7, wherein said articles are welding rods.
 9. The container of claim 7, wherein said articles are welding electrodes.
 10. The container of claim 7: wherein said articles are sealed inside said container with said lid; wherein said VCI product is inside said container; wherein said articles may be one or more of: welding consumables, welding rods, wire, brazing, tool and die repair, consumables for shielded metal arc welding, consumables for gas metal arc welding, consumables for gas tungsten arc welding, or consumables for oxyacetylene welding. 